Wire laser additively reinforced blanks: Effect of the laser power on the bending strength of a single layer reinforcement

This study investigates the application of Wire Laser Metal Deposition (w-LMD), a form of Directed Energy Deposition (DED) additive manufacturing, to enhance the production process of automotive components, specifically through the development of patchwork blanks with localized reinforcements. The research focuses on reinforcing 22MnB5 steel sheets with beads of 316L steel using a laser beam at various power levels, aiming to achieve maximum strength with minimal use of material. The resulting components, referred to as wire-Laser Additively Reinforced Blanks (w-LARB), demonstrated a substantial increase in strength, up to 87%, as verified by bending tests. Notably, the study reveals that a relatively low laser power can still yield significant mechanical improvements, underlining the efficiency of the process in terms of material usage and energy consumption. Furthermore, the high repeatability of the w-LMD process confirms its potential for widespread industrial adoption in automotive manufacturing.